Sumitomo (SHI) Demag is expanding its medical portfolio with a high-throughput demonstration at K 2025, presenting the latest 420 t PAC-E injection moulding machine configured for ultra-clean, fast-cycling production. The exhibit centres on a 48-cavity Med-Cup cell designed with Zubler Handling AG and Otto-Hofstetter AG, aligning cleanroom-compatible mechanics with short cycle times and precise part handling. The application manufactures and stacks 30 ml medication dispensing cups at up to 57,600 parts per hour, addressing thin-wall geometries with high injection speeds and repeatability. The clean-toggle architecture is engineered for sustained performance in mass production, supporting stringent hygiene requirements typical of medical moulding. Setting a three-second benchmark for healthcare components such as cups and centrifuge tube bodies, the PAC-E cell integrates automated extraction, cavity-specific stacking and inline vision control. According to Director Business Development Medical Andreas Montag, the 420 t PAC-E can reach around 432 million components annually in this configuration, while the complete production cell remains comparatively compact versus all-electric systems designed for similar outputs.
The 48-cavity tool from Otto-Hofstetter injects centrally via a point gate with a shot weight of approximately 70 grams. Thermal management is provided by a balanced cooling layout with 29 water circuits, contributing to stable processing conditions and continuous operation. For maintainability, the tool is designed for front-side demoulding and access, simplifying servicing and changeovers.
Quality control is executed inline using high-definition vision cameras installed along the extraction axis by Zubler Handling. The 100 percent inspection system processes 96 images per extraction, performing anomaly detection and dimensional checks with an accuracy of 0.05 millimetres. After demoulding, cups are deposited on a rotary table comprising two sections, each with 48 dedicated compartments mapped to the corresponding cavities. A pick-and-place robot subsequently handles eight stacks at once, separating them into good or reject cases without interrupting the moulding sequence. Montag notes both the tempo and traceability advantages of this approach: "The speed of the extraction is seamless and is actually much faster than components free falling. But one of the main advantages is the quality control. Each cavity has its own compartment. So, if there are any quality issues in a particular stack, these can be segregated, fully investigated and resolved without wasting the entire production consignment."
Clean-toggle performance and cell integration
The medical PAC-E configuration combines rapid injection, short clamp stroke and clean mechanics to support thin-wall, multi-cavity moulding. Working with Zubler Handling’s intelligent stacking and vision hardware and Otto-Hofstetter’s tooling, the cell ties high-cadence extraction to cavity-specific traceability. The compact footprint of the system, including peripherals, is positioned to fit within constrained cleanroom layouts while maintaining output levels typically associated with much larger installations.
The Medical Cup Production can be experienced live at K 2025.
Inline inspection and stacking logistics
By allocating each cavity’s output to a dedicated compartment and associating it with high-resolution image data, the cell enables targeted intervention. Stacks suspected of deviation can be quarantined and traced back to cavity position for root-cause analysis, reducing scrap risk and safeguarding overall lot quality. The ability to move eight stacks concurrently preserves cycle synchronicity and minimizes handling dwell times.
Additional medical demonstrations
On the Nexus stand, an IntElect 130 t LSR injection moulding setup produces medical valves using coordinated automation and post-processing. In a 23-second total cycle, a six-axis robot demoulds 16 parts and transfers them to a slitting station, where electrically driven knives complete the cuts while the next moulding shot proceeds in parallel. Optional camera inspection and traceable packaging illustrate a fully autonomous 24-hour production concept.
At the Sepro booth, an IntElect S 130 t cell will manufacture 15 ml centrifuge tube caps using a 48-cavity tool supplied by Jestar Mold Tool. With a ten-second cycle time, the application highlights high-output cap production suitable for laboratory disposables and diagnostic workflows.
Press briefing at K 2025
A press briefing by Anatol Sattel and Martin Pütz, Senior Director Technology, is scheduled for Thursday, October 9th, at 10:30 am. Attendance confirmations can be sent to simon.wild@shi-g.com.
Engineered with precision: 30 ml medical cups from the PAC-E 420 t, meeting the highest hygiene standards
